warning YAMAHA YZF-R7 1999 Repair Manual

7 - 48
CHAS
2. Install:
• copper washers
• clutch hose 1
• union bolt 2
WARNINGWARNING
Proper clutch hose routing is essential
to insure safe motorcycle operation.
Refer to “CABLE ROUTING”.
ACHTUNG:CAUTION:
When installing the clutch hose onto
the clutch master cylinder, make sure
that the pipe a touches the projection
b.
2
2

a
a
1 1
b
b
New
T R..26 Nm (2.6 m · kg, 19 ft · lb)
3. Fill:
• clutch fluid reservoir
(with the specified amount of the rec-
ommended clutch fluid)
Recommended clutch fluid
Brake fluid DOT 4
WARNINGWARNING
• Use only the designated clutch fluid.
Other clutch fluids may cause the rub-
ber seals to deteriorate, causing leak-
age and poor clutch performance.
• Refill with the same type of clutch
fluid that is already in the system.
Mixing clutch fluids may result in a
harmful chemical reaction, leading to
poor clutch performance.
• When refilling, be careful that water
does not enter the reservoir. Water
will significantly lower the boiling
point of the clutch fluid and could
cause vapor lock.
ACHTUNG:CAUTION:
Clutch fluid may damage painted sur-
faces or plastic parts. Therefore, always
clean up any spilt clutch fluid immedi-
ately.
HYDRAULIC CLUTCH

7 - 52
CHAS
EAS00313
DISASSEMBLING THE CLUTCH RELEASE
CYLINDER
1. Remove:
• dust seal 1
• clutch release cylinder piston 2
• spring 3
• oil seal 4
t t t t t t t t t t t t t t t t t t t t t t t t t t t
a. Blow compressed air into the clutch
hose joint opening a to force out the
piston from the clutch release cylin-
der.
WARNINGWARNING
• Cover the clutch release cylinder with
a rag. Be careful not to get injured
when the piston is expelled from the
clutch release cylinder.
• Never try to pry out the clutch release
cylinder piston.
b. Remove the clutch release cylinder oil
seal.
s s s s s s s s s s s s s s s s s s s s s s s s s s s
EAS00314
CHECKING THE CLUTCH RELEASE
CYLINDER
1. Check:
• clutch release cylinder body 1
Cracks/damage ® Replace the clutch
release cylinder.
• clutch release cylinder 2
• clutch release cylinder piston 3
Rust/scratches/wear ® Replace the
clutch release cylinder and clutch
release cylinder piston as a set.
1
1

2
2

3
3

HYDRAULIC CLUTCH

7 - 53
CHAS
EAS00315
ASSEMBLING AND INSTALLING THE
CLUTCH RELEASE CYLINDER
WARNINGWARNING
• Before installation, all internal clutch
components must be cleaned and
lubricated with clean or new clutch
fluid.
• Never use solvents on internal clutch
components as they will cause the oil
seal and dust seal to swell and distort.
• Whenever a clutch release cylinder is
disassembled, replace the oil seal and
dust seal.
Recommended clutch fluid
Brake fluid DOT 4
1. Check:
• copper washer 1
• clutch hose 2
• union bolt 3
WARNINGWARNING
Proper clutch hose routing is essential
to insure safe motorcycle operation.
Refer to “CABLE ROUTING”.
ACHTUNG:CAUTION:
When installing the clutch hose onto the
clutch release cylinder, make sure that
the pipe a touches the projection b.
2. Fill:
• clutch fluid reservoir
(with the specified amount of the rec-
ommended clutch fluid)
WARNINGWARNING
• Use only the designated clutch fluid.
Other clutch fluids may cause the rub-
ber seals to deteriorate, causing leak-
age and poor clutch performance.
• Refill with the same type of clutch
fluid that is already in the system.
Mixing clutch fluids may result in a
harmful chemical reaction, leading to
poor clutch performance.Recommended clutch fluid
Brake fluid DOT 4
2
2

3

3

a a
1
1

b b
New
T R..26 Nm (2.6 m · kg, 19 ft · lb)
HYDRAULIC CLUTCH

7 - 58
CHAS
EB703100
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of
the front fork legs.
1. Stand the motorcycle on a level surface.
WARNINGWARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand
so that the front wheel is elevated.
2. Adjust:
• spring preload
NOTE:
Turn the adjusting bolt 1 in fully so that
it sits lightly. Refer to “ADJUSTING THE
FRONT FORK LEGS” in chapter 3.
1
1

3. Loosen:
• upper bracket pinch bolt 1
• cap bolt 2
(with the front fork cap bolt wrench)
• handlebar pinch bolts
• lower bracket pinch bolts
WARNINGWARNING
Before loosening the upper and lower
bracket pinch bolts and handlebar pinch
bolt, support the front fork leg.
4. Remove:
• front fork leg
Front fork cap bolt wrench:
90890-01472
1
1
2

2

EB703113
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of
the front fork legs.
1. Remove:
• cap bolt 1
(from the damper rod assembly)
• straight key
• washer
• damper adjusting rod
4
51
2
3
FRONT FORK

7 - 59
CHAS
• nut 2
• spring seat 3
• spacer
t t t t t t t t t t t t t t t t t t t t t t t t t t t
a. Press down on the spacer with the
fork spring compressor 4.
b. Install the rod holder 5 between the
nut 2 and the spring seat 3.
NOTE:
Use the side of the rod holder that is
marked “A”.
c. Loosen the nut.
d. Remove the cap bolt, straight key,
washer and damper adjusting rod.
e. Remove the rod holder and fork
spring compressor.
WARNINGWARNING
The fork spring is compressed.
f. Remove the nut, spring seat and
spacer.
s s s s s s s s s s s s s s s s s s s s s s s s s s s
Fork spring compressor
90890-01441
Rod holder
90890-01434
2. Drain:
• fork oil
NOTE:
Stroke the damper rod 1 several times
while draining the fork oil.
3. Remove:
• outer tube
(from inner tube)
4. Remove:
• dust seal
• oil seal clip 1
• oil seal
• washer
(with a flat-head screwdriver)
FRONT FORK

7 - 60
CHAS
5. Remove:
• damper rod assembly
(with the damper rod holder 1)
Damper rod holder
90890-01473
EB703401
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of
the front fork legs.
1. Check:
• inner tube 1
• outer tube 2
Bends/damage/scratches ® Replace.
WARNINGWARNING
Do not attempt to straighten a bent
inner tube as this may dangerously
weaken it.
2. Measure:
• spring free length a
Out of specification ® Replace.
Spring free length limit
240 mm (9.45 in)
3. Check:
• damper rod 1
Damage/wear ® Replace.
Obstruction ® Blow out all of the oil
passages with compressed air.
ACHTUNG:CAUTION:
• The front fork leg has a built-in
damper adjusting rod and a very
sophisticated internal construction,
which are particularly sensitive to for-
eign material.
• When disassembling and assembling
the front fork leg, do not allow any for-
eign material to enter the front fork.
FRONT FORK

7 - 61
CHAS

4. Check:
• cap bolt O-ring
Damage/wear
®
Replace.
EB703702
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of
the front fork legs.
WARNINGWARNING

• Make sure that the oil levels in both
front fork legs are equal.
• Uneven oil levels can result in poor
handling and a loss of stability.
NOTE:

• When assembling the front fork leg, be
sure to replace the following parts:
- inner tube bushing
- outer tube bushing
- oil seal
- dust seal
• Before assembling the front fork leg,
make sure that all of the components
are clean.
1. Install:
• damper rod assembly
1
ACHTUNG:CAUTION:

Allow the damper rod assembly to slide
slowly down the inner tube
2
until it
protrudes from the bottom of the inner
tube. Be careful not to damage the inner
tube.
NOTE:

Be sure that the clip
3
is still correctly
installed.
2. Lubricate:
• inner tube’s outer surface
Recommended lubricant
Yamaha fork and shock oil
M1 or equivalent
FRONT FORK

7 - 65
CHAS
c. Install the fork spring, spacer, spring
seat and nut.
NOTE:
Finger tighten the nut onto the winding
at the damper rod end.
d. Install the rod puller and adapter onto
the damper rod.
e. Press down on the spacer with the
fork spring compressor 9.
f. Pull up the rod puller and install the
rod holder 0 between the nut 4 and
the spring seat.
NOTE:
Use the side of the rod holder that is
marked “A”.
g. Remove the rod puller and adapter.
h. Install the damper adjusting rod,
washer, straight key and cap bolt, and
then finger tighten the cap bolt.
NOTE:
• Make sure that the spring preload
adjusting bolt at the top of cap bolt is
fully, but lightly tightened.
• Insert the cap bolt fully into the
damper rod.
i. Hold the cap bolt and tighten the nut.
j. Remove the rod holder and fork
spring compressor.
WARNINGWARNING
• The fork spring is compressed.
• Always use a new cap bolt O-ring.
s s s s s s s s s s s s s s s s s s s s s s s s s s s
Rod puller
90890-01437
Adapter
90890-01436
Fork spring compressor
90890-01441
Rod holder
90890-01434
T R..
Nut
25 Nm (2.5 m • kg, 18 ft • lb)
9
0
4
FRONT FORK

7 - 66
CHAS
17.Install:
• outer tube
(onto the cap bolt)
NOTE:
Temporarily tighten the cap bolt.
EB703710
INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of
the front fork legs.
1. Install:
• front fork leg
Temporarily tighten the upper and
lower bracket pinch bolts.
NOTE:
Align the top of the upper bracket with
fourth groove below the cap bolt.
2. Tighten:
• lower bracket pinch bolt 1, 2, 3
NOTE:
Tighten the lower bracket pinch bolts 1,
2 and 3 in the given order and in two
stages. Finally, tighten the pinch bolt 1
once more.
• handlebar pinch bolt
• cap bolt
• upper bracket pinch bolt
WARNINGWARNING
Make sure that the brake hoses are
routed properly.
3. Adjust:
• spring preload
• rebound damping
• compression damping
Refer to “ADJUSTING THE FRONT
FORK LEGS” in chapter 3.
1
1
2

2

3

3

T R..11 Nm (1.1 m · kg, 8.0 ft · lb)
T R..13 Nm (1.3 m · kg, 9.4 ft · lb)
T R..25 Nm (2.5 m · kg, 18 ft · lb)
T R..26 Nm (2.6 m · kg, 19 ft · lb)
FRONT FORK

7 - 69
CHAS
EB704101
REMOVING THE HANDLEBARS
1. Stand the motorcycle on a level surface.
WARNINGWARNING
Securely support the motorcycle so that
there is no danger of it falling over.
2. Remove:
• handlebar grip
NOTE:
Blow compressed air between the left
handlebar and the handlebar grip, and
gradually push the grip off the handle-
bar.
EB704401
CHECKING THE HANDLEBARS
1. Check:
• left handlebar
• right handlebar
Bends/cracks/damage ® Replace.
WARNINGWARNING
Do not attempt to straighten bent han-
dlebars as this may dangerously
weaken them.
EB704704
INSTALLING THE HANDLEBARS
1. Install:
• brake master cylinder holder 1
ACHTUNG:CAUTION:
• Install the brake master cylinder
holder with the “UP” mark facing up.
• First, tighten the upper bolt, then the
lower bolt.
NOTE:
• Align the mating surfaces of the brake
master cylinder holder with the punch
mark a in the right handlebar.
• There should be 2 mm of clearance
between the right handlebar switch
and the brake master cylinder holder.
UP UP
UP
a
a
1
1

T R..13 Nm (1.3 m · kg, 9.4 ft · lb)
HANDLEBARS